Plug-in relay



Feb. 27, 1951 2,543,000

G. DEAKIN PLUG-IN RELAY Filed March 12, 1946 3 Sheets-Sheet 1 se 5028 25 l 29 FIGLZ.

7 52 el eo 90 JNVENTOR. 89 GERALD DEAKIN WMA ATTORNEY G. DEAKIN PLUG-IN RELAY Feb. 27, 1951 3 Sheets-Sheet 2 FIG. .5.

Filed March 12 1946 ATTORN Y 4 :WEA/ron. 'GERALD DEAKIN Feb. 27, 1951 G. DEAKIN 2,543,000

PLUG-IN RELAY Filed larCh 12 1946 3 Sheets-Sheet 5 FIGS.

FIGJB/03 mmm im fom/@m mmm 90 :mm ma [09 i /V C D 88] i 0/ i 88 c: D mmm 90 im@ .uw Emmi im@ Ten mmm@ Q09 mmim 9 mm1@ Q/ Vim@4 Pair /02 INVENToR.

GERALD DEAKIN AT TORNEY Patented Feb. 27, 1951 PLUG-1N RELAY Gerald Deakin, New York, N. Y., assigner to International Standard Electric Corporation, New York, N. Y., a corporation of Delaware Application March 12, 1946, Serial No. 653,896

7 Claims. 1

The present invention relates to relays and connections therefor and an important object of the invention is to provide a novel and advantageous plugin relay adapted for use in communication systems such as telephone systems.

Another object of the invention is to provide a novel and advantageous relay assembly.

Another object of the invention is to provide a novel and advantageous socket assembly for use with said plug-in relay.

Still another object of the invention is to provide novel and advantageous means for mounting said socket.

Yet another object of the invention is to provide novel and advantageous means for mounting said socket whereby the socket can be readily applied or removed.

A further object oi' the invention is to provide a plug-in relay wherein the ends of conductor springs including contact springs, serve as plug-in terminals.

A still further object of the invention is to provide a dust-tight multi-contact relay.

Another object of the invention is to cheapen manufacture by permitting the use of contact springs formed and cut from a continuous strip of suitable spring metal such as bronze without punching, drilling, trimming, or other machine operation. Waste of labor and material is thus eliminated.

A further object of the invention is to provide a relay having novel and advantageous dust-excluding means.

According to the present invention manufacture may be further cheapened by mounting the sockets with their easily accessible and clearly marked terminals on their mounting plates or frames and then wiring them without waiting for the relays, which may be plugged in at any time thereafter in the factory or on the job. At the present time it is necessary to delay wiring until the relays are finished and mounted. Wiring is diflicult because of the awkward and unmarked arrangement of the present relay terminals. Plug in relays may be replaced easily, and defective relays may be examined on a bench rather than on the bay. In large circuits, it is very diicult to test and adiust relays on the bay. Generally it is necessary to perform such operations as unsoldering and insulating certain relay contacts. Changes and adjustments so made take considerable time, thereby placing an important circuit out of service for a considerable period. However. with plug-in relays, a new relay may be substituted immediately i'or the 2 defective or doubtful relay and there will be a minimum of interruption for the circuit. The present invention enables economical manufacture and easy assembly and adjustment.

Other objects, features and advantages will appear upon consideration of the following detailed description and of the drawings, in which Fig. 1 is an elevation of a plug-in relay assembly embodying the present invention, the relay being in upright position with the front wall broken away along the line I-I of Fig. 2;

Fig. 2 is a section taken along the line 2-2 of Fig. 1;

Fig. 3 is a section taken along the line 3-3 of Fig. 1, the socket and support being omitted:

Fig. 4 is a section taken along the line l-l of Fig. 1. the socket and support being omitted;

Fig. 5 is a fragmentary top plan view of the unitary central portion of the base of the relay;

Fig. 6 is a sectional view along the line 6-6 of Fig. 5;

Fig. '1 is a plan view of the support for these sockets;

Fig. 8 is a section on the line 8-8 of Fig. '1;

Fig. 9 is a bottom plan view of the assembled base oi' the relay unit;

Fig. 10 is a top plan view of a socket adapted to carry two relays;

Fig. 11 is a view taken along the line 9 9 of Fig. 10 looking in the direction of the arrows;

Fig. l2 is a fragmentary elevation taken along the line lll-I0 of Fig. 11 looking in the direction of the arrows;

Fig. 13 is a fragmentary bottom view of the socket structure of Fig. B; and

Fig. 14 is a perspective view of one of the spring contact members or jacks to receive the contact prong of the relay.

Referring to the drawings, Figs. 1. 2. 3, 4, 5, 6 and 9 illustrate a plug-in relay i5 comprising a core I6, a spool or ycoll I1 surrounding said core. and an L-shaped return pole piece I8 which is preferably of rectangular cross-section. The core I6 is of circular cross-section and has a screw-threaded reduced lower end I9 which passes through a corresponding opening in the base oi' said L-shaped pole piece IB and into a nut 20 which when tightened clamps said core and pole piece firmly together. Below the nut 20, said threaded lower end passes through a bore in a magnet base 22 of insulating material. constituting an intermediate or body portion of base 23 of the relay. Said body portion 22 is countersunk at the upper end of said bore to receive the nut 20 and enable the central part o! said body portion 22 to engage the base o! said L-shaped pole piece i8, and is countersunk at the lower end of said bore to receive a nut 2| on said threaded lower end l! of the core. By tightening said nut 24, the magnet base may be secured firmly to the pole piece i3 and the magnet core I6.

At the outer face of the upper end of the upright portion of the return pole piece i3 is an armature bearing plate 25 firmly attached to the pole piece as by spot welding. Said plate 2l may be somewhat wider than the pole piece I3 and at a level slightly above the top oi' the return pole piece may be out away to provide an upright portion 23 of reduced width and two outwardly extending shoulders 21 with aligned horizontal bearing edges 23 at the outer face of said plant 23. Said bearing edges 28 provide a pivotal axis for an armature 29 illustrated as a plate having at one end projecting lugs 30 passing on opposite sides ot said upright portion 2B of plate 25 and bent down intermediate their ends to form sharp obtuse-angle corners to cooperate with said bearing edges 23 which act as knife-edge bearings.

Preferably said lugs 30 project laterally beyond the sides of the main body of the armature which overlies and nearly covers the upper end oi the magnet. Mounted on said armature just back of the lugs 30 is the middle portion of a sheet metal member 3| of U-shape of which the sides or arms 32 extend downwardly below the lower edge of plate 25 and are continued as arms 33 extending away from the magnet beneath the portions of plate 25 projecting beyond the sides of the return pole piece i3. A member 34. preferably round. is mounted, as by means of pivots 33A, in arms 33 and engages armature springs 3l which normally engage back contact springs 33 but are shiftable by the armature 23. upon energization of the magnet, into contact with the front contact springs 31. As illustrated. there are i'our sets of springs 35, 3B and 31. All of these springs are provided with suitable contact points.

The springs 35, 36 and 31 are secured in a manner to be described hereinafter in insulating mater iai of the base 23 of the relay and project from the lower side thereof to provide plug-in terminals 33. Beneath the arms 33 and member 3l there is a frame Il of insulating material. preferably rectangular, secured to the upright portion oi the return pole piece IB by suitable means such as a screw I3 passing through a lug lla projecting. downwardly from said frame and integral therewith, and threaded into said upright portion oi' the return pole piece Il. The side 44 o! the frame Il next to the return pole piece is provided with recesses l to receive springs 36 and constitutes a spring guide. In the same manner, the opposite side IB of the frame has recesses or notches I1 to receive springs 31 and constitutes a spring guide.

At the opposite side of the magnet from springs 35, 36 and 31 are two parallel rows of i'our springs each xed in insulating material oi' said base 23 in a manner to be described hereinafter, and projecting from the lower side thereof to provide plug-in terminals 38. The two inner springs I3 of the inner row are coil terminals projecting relatively short distances above the base and the inner springs l! of the outer row are also coil terminals. The coil terminals are connected to insulated wires 43a of the magnet coil l1. The inner row also includes two end springs 60 which incline slightly away from the coil above the base 23 and although normally in contact with corresponding springs Il of the outer row, preierably through suitable contact points, may be withdrawn therefrom upon energization ot the relay magnet and consequent movement of the armature 2l. To this end the amature 23 is provided with a central tongue B2 projecting to the right (Fig. 2) beyond the cap of the spool and over this tongue is placed, and secured as by welding. the dat base of a U-shaped member B3 oi' sheet metal oi' which the sides or arms El extend downwardly in parallel planes.

At their lower ends arms 3l are split to spring over reduced connections between a central section of an element Il and end portions 56 which engage the outer faces o! springs B3 above the upper ends of springs Il. Energization of the relay will therefore cause breaking or electrical connections between inner springs 53 and outer springs or back contacts Il.

The springs 3l and Il urge said armature 23 upwardly and tend to produce an air gap beftween the upper end of the core i3 and a contact point I1 on the lower tace of the armature. To limit and adjust said air gap, there may be secured to the upper surface of the armature as by welding. an air gap clip Il in the form of a metal strip with its lett portion lying tlat on said armature and secured thereto as by welding and with a right portion inclined upwardly away from the upper part oi pole piece I3. The clip 53 may be engaged by the rounded end of a screw 33 threaded through the upward projection 23 and locked in adjusted position by a lock nut GII. The action of the screw Il on the inclined upper surface oi' the right portion o! clip 53 enables accurate adiustment.

For the purposes of ready assembly and disassembly and i'or adjustment oi' the tensions of the leaf springs, the portion of said springs are arranged in lines between parts of the base including the central part 22 and are gripped therebetween. The springs are flat and where they pass through the base 23 are bent preferably in curves which may be arcs of circles connected to substantially straight lines by reverse curves, to hold them against longitudinal movement and also against turning. These parts of the flat springs rest in grooves having bottoms of substantially the same shapes as the wires and being formed in lateral faces of said members corresponding to the shapes of said wires. In the particular forms of the parts as disclosed, the bent portions of the springs or wires are pressed to the bottoms of said grooves by corresponding ridges on the corresponding faces of adjacent gripping members. Although nat springs are disclosed, springs oi other cross sections such as round may be used. It should be understood that the edges of the parts gripping the wires have substantially the same shape in cross-section as the bottoms of the grooves.

The springs 33 are gripped against the left side (Fig. l) of the base base member 22 by means oi' a member or bar 3| the springs 35 are gripped against the left side oi' member Bl by means of a member 62, and the springs 31 are gripped against the member t2 by means oi' an outside member 33. At the other side oi the base member 22 the two springs 43 and the two springs 5I) of the inner row are gripped against member 22 by a member Il and the spring I8 and 5I are gripped against member 34 by a member 65. Aiter all parts oi the base are assembled in this way. spring clips 3l (Figs. l, 3 and 4) are applied thereto at opposite sides of said base 23, being seated in grooves provided for that purpose.

The curved intermediate parts o! the adjacent faces of members 22, ll, B2, 63. $4 and 8l may be considered as generated about horizontal axes parallel to said adjacent faces and to the top and the bottom of the base of part 22. The curved intermediate parts of the springs with reverse curves at the ends of said intermediate parts make it easy to support the springs against longitudinal displacement and against turning movements.

It will be evident that bent portions of the springs although formed with convex sides and with the opposite sides concave, need not be curved but may be made with successive straight line portions, the gripping surfaces being correspondingly shaped. In these cases the concave and convex surfaces of the parts may be considered as generated by lines moving parallel to xed horizontal lines or axes. The parts of the spring-clamping surfaces of the insulating blocks or members at the base oi the relay. above the concave and convex parts. are inclined at the proper angles to give a preliminary adjustment of the springs for either a make or break contact.

Not only is the construction of the base 23 of advantage in assembling the contact springs and coil terminals in said base, but it facilitates adjustment of the tensions of said springs, as will be explained more fully hereinafter.

In order to provide more secure holding of contact springs 36 against the left side of magnet base 22 (Fig` 1) and contact springs 50 and coil terminals 48 against the right side thereof, said magnet base is provided with an upwardly extending flange 61 (Fig. 6). The left side of magnet base 22 is provided with a groove 6B for each contact spring 36. Said groove 68 is of greater depth than the thickness of spring 36 and is narrowed from the mouth of the groove toward the bottom thereof, thus acting to seat the spring accurately as to lateral position and direction and otherwise facilitating the seating of the spring against the bottom of the groove 8B. The groove 6B might be of triangular shape.

'I'he bottom of each groove 6B has, at a part spaced from the lower face of said magnet base 22 by a strip Bil and from the upper face by a strip 10, a concave portion 1| curved in a circular cylindrical surface about a horizontal axis. The lower strip 69 is vertical but the upper strip extends upwardly and to the right so that the part of spring 36 above the base 22 will be inclined to the right and pressed against the spring guide 44. The left face of magnet base 22 has the same general contour as the bottom of each groove 68.

Corresponding to each groove BB at the left of magnet base 22, there is at the right of member or bar 6I a rib 12 (Fig. 9) adapted to enter the groove and clamp the corresponding spring 36 therein. The edge of each rib 'I2 will have a vertical lower portion to cooperate with the vertical lower strip liil (Fig. 6), a convexly curved intermediate portion to cooperate with the concavely curved strip 1|, and an upper straight portion which determines the inclination of that part of the spring 36 within the limit determined by the part 10. Between the ribs 12 which are narrow enough to enter the grooves BB there are grooves 13 (Fig. 9) wide enough to receive teeth 14 (Figs. 5 and 9) between the grooves 68.

As indicated in Fig. 1, the upper part of each groove at the lett of bar Il and the corresponding rib at the right of bar 82 are so positioned that springs 35 are urged to the right to contact at their upper ends with springs 36. The bars 62 and 63 are so shaped at their adjacent sides as to urge the upper ends of springs 31 to the left against the spring guide 46.

At the right of said magnet base 22, the edge thereof is similar in form to that at the leit except that the intermediate portion is concave to the right and the upper end of the base of each groove is substantially vertical. There is no need in this case to provide any substantial inclination of the springs 5I! above the base 2l. They are, however, bent slightly away from the magnet to enable suiilcient inward movement to break contact with springs 5I. The springs 50 and coil terminals 48 are pressed into the grooves in magnet base 22 by ribs at the left of member or bar B4. The springs 5| and coil terminals 49 are similarly gripped between bar 64 and bar B5.

The assembled base 23 is provided with a ledge extending around the upper part thereof and at the base of a rectangular top portion. 'Ihis ledge may be used to support the open lower end of a cover or casing 8| which fits closely around said top portion and around the outer side and two ends of the frame 4I. Said cover is provided at its top with an opening 82 to receive the upper end of the reduced extension 2i of the armature bearing plate 25, and a tubular extension 83 which extends to the upper end of said extension 26 and is open at the top.

The upper end of extension 26 is provided with an opening 84 therethrough in alignment with openings 35 in opposite walls of said tubular extension 83. The cover 8| may be secured in position over the relay by inserting a bolt 8B through the openings 35 and the opening B4 with its head against one side of the tubular extension 83. At the other side of said extension 83, the shank of said bolt is provided with a groove to receive the split end of a clip 81 in the form of a thin plate having a part extending horizontally over the top of the adjacent side oi' said tubular extension. In this manner each relay may be made substantially dust-proof.

Of course the relay as hereinbefore described might be supported in any suitable way and all of the terminals projecting downwardly from the base might be connected to suitable conductors. However, it is very important to be able to remove a relay and also to apply one readily. To this end it is important to have a socket structure into which the terminals at the base of the relay may be inserted. It is also important to provide socket assemblies which are economical to manufacture, assemble and install and in which parts of the socket structure may readily be removed or applied without interference with other parts.

The ends of the springs projecting from the lower face of base 23 of the relay constitute plug-in terminals 3B. A suitable relay socket 88 comprising a plaie or block B9 is best shown in Figs. 8 through l2. This socket is adapted to accommodate two relays I5. It should be understood, however, that the socket might be small enough to accommodate only one relay or large enough to accommodate more than two relays. Each relay may be properly positioned on the socket by inserting into a suitable opening in the socket a member Si projecting downwardly from the base of the relay. Said member 9| auaooo 7 may have a round body portion with a rib Il adapted to engage a groove in opening 99 to insure positioning of the relay.

The body 99 of the socket 99 may be in the form of a plate or block of suitable material such molded plastic with a central longitudinally extending groove 94 therein at its rear face. At the left of said groove 94. said block is provided with three rows of passages or openings 99 corresponding to the plug-in terminals projecting downwardly i'rom base 29 at the left of Fig. l. At the right of said groove there are two rows of passages 95 corresponding to the plug-in terminals at the right of Fig. l. Said passages 99 are designed to receive socket springs or jacks 99.

Each socket spring 96 is formed of a metal strip of resilient character and oi substantially uniform width throughout its length. Said socket spring has two arms 91 diverging from a fold or bend thereof and toward their outer ends these arms are turned outwardly at right angles to provide shoulder portions or shoulders 9B (Fig. 14). At the outer ends of these shoulders the arms are turned through right angles into parallelism with the main portions of said arms. The arms are then turned inwardly and outwardly so that provision is made oi inwardly convex portions 99 adapted to engage each other when the parts at opposite sidesoi the bend are pressed together and to receive therebetween a contact terminal 99 oi the relay.

Each of said passages 95 is provided with an upper part of generally rectangular cross-section to receive the upper part of a socket spring and a reduced lower part `just suflcient in crosssection to receive the folded together parts at opposite sides of the bend or fold. When the outer ends of said arms of a socket spring are pressed together the device may be inserted into an opening 95 until shoulders 98 engage shoulders |99 formed at the inner end of the reduced portion of the passage. At proper points the arms 91 are provided at their edges with barbs |9I. each of which is formed by suitable cutting at the edge of an arm 91 and displacement of the end of the part so cut, out of the plane of the arm. These barbs |9| will be forced back in inserting the socket spring and will then snap into position at the lower face of the block 99 and prevent outward movement. The holding action of the barbs is illustrated in Figs. 11, l2 and 13. The holding by said barbs is so effective that a socket spring might be divided at the bend into two parts. These two parts could be inserted together and would be iirmly heid.

Adjacent the bend thereof each socket spring 98 is provided with aligned openings |92 for convenience in connecting a wire to said spring. At the bottom i'aces thereof, both relay base 23 and socket body 99 may be provided with suitable indications including numbers to assure the making of connections to the proper wires. As disclosed, each socket 88 is designed to carry two relays i across the ends of said groove 94 but at the opposite i'ace of block 89.

Each socket body or block 99 is cut out at its rear face and across the end portions at opposite sides of said grooves 94 to provide shoulders |93 (Fig. l2) to rest against the edges of parallel metal sides |94 (Figs. 7 and 8) of a support |95 (Fig. l1) for a plurality o! said socket blocks 99, and to enable the part of the block to the rear oi' such shoulders to t between said sides |94. Joining the outer edges of said sides |94 are cross members |99 intekral therewith and in the form or inverted channels comprising inturned nanges |91 and of a size ior the grooved portions of socket bodies 89 to be placed thereover (Fig. 1l). As illustrated, the cross members |99 which correspond to rungs of a ladder project outwardly beyond the edges oi' the parallel sides |94. Each block 89 is secured to the corresponding cross member |99 in a suitable member as by screws |99 passing through openings in the base of the cross member and into openings |99 in the socket body 99. The screws |98 may be oi' the seli'- threading type. The cross members |99 are spaced to assure sufilclent clearance between blocks 99 on two successive cross members.

As indicated on Fig. 7, the relays I9 mounted on each cross member |99 are separated and due to this separation, and to the covers 9| there should be no interference between the magnetic circuits oi the relays.

Although the relay disclosed is of the break before make type, the invention may also apply to a relay oi' the make before break type but in this modied form the arrangement at the right of Fig. 1 would be changed so that each time the coil is energized there would be contact breaks.

'Ihe relays are shown as associated in groups of two on each socket body 99, but the arrangement may be modified to apply to one relay or to more than two relays on each socket body or base B9.

The arrangement oi' the relay with sets of conductor springs secured in the base at opposite sides of the relay makes it possible to limit the width of the relay so that said width is only slightly greater than the diameter of the head of the spool o1' the magnet. Said base is held at both ends to the socket member and across the groove 94 at the rear face of the socket block 99, by the two groups oi' plug-in terminals, and neither oi' said ends is likely to work away from said socket block.

The location of cross members |99 in grooves 94 ot socket blocks assists in positioning the bases of the relay and holding them against movement transverse to said cross members. The projection of a portion o1' each socket block between the sides |94 of the support serves to position the blocks in directions transverse to said sides |94 and longitudinally with respect to said cross members. The engagement of said shoulders |93 with the edges oi' sides |94 acts to prevent any rocking movement or the socket blocks 99 on cross members |98.

Although the conductor springs are disclosed as pre-shaped where they pass through the relay base, there may be instances where the bends in the springs are produced by subjecting the springs to pressure between the bars or parts o! the relay base.

The socket bodies 89 are readily molded from suitable insulating material and upon forcing the socket springs 99 into said passages 95, the sockets will be readv for use. Each support |95 may readily be formed from a metal strip by cutting and bending.

It should be understood that various changes may be made and that certain features may be used without others without departing from the true scope and spirit oi' the invention.

What I claim is:

1. A plug-in relay comprising a magnet, an insulating base carrying said magnet, sets o! springs including contact springs secured in said base projecting from said base as plug-in terminals. said springs being bent at portions intermediate the surfaces o! said base but being straight at the ends of said bent portions, said base comprising a magnet base for supporting said magnet and bars parallel to the adjacent side of the magnet base, said magnet base and bars receiving said springs in rows therebetween and having spring engaging surfaces fitting against said bent portions of the springs, and said magnet base and bars being locked together by suitable means.

2. In a plug-in relay, a plurality of conductor springs arranged in parallel and having portions similarly bent so as to be convex at one side and concave at the other, but having straight portions above and below said bent portions, and a base comprising parallel bars having respective convex and concave surfaces operatively positioned to engage opposite sides of said bent portions and to determine the direction of emergence of each of said springs. the portions of each spring between said bars and adjacent the point of emergence being held displaced from its normal position, and means for clamping said bars together.

3. The combination according to claim 2 wherein said bent portions are in the form of circular arcs.

4. The combination according to claim 2 wherein said bent portions are in the form of circular arcs and certain edges of said bars have grooves in which springs are positioned.

5. The combination according to claim 2 wherein said bent portions are completely received in grooves in one of two adjacent surfaces, and the adjacent surface of another bar is provided with ridges to enter said grooves and press the springs against the bottoms thereof.

6. In a device of the character described, a plurality of conductor springs arranged in parallel, a base comprising parallel bars engaging each of said springs on opposite sides and means for clamping said bars together with said springs therebetween, the portions of the various springs of each row between the upper and lower faces of said base being bent in the same way intermediate the ends of said portions and in planes perpendicular to said bars, and the adjacent edges of said bars having spring-engaging surfaces tting against the bent portions of said springs.

7. In a device of the character described, the combination, as claimed in claim 6, in which said springs are arranged in rows parallel to said bars, each row of springs being supported between two adjacent bars.

GERALD DEAKIN.

REFERENCES CITED The following references are of record in the le of this patent:

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